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The property right in work regarding all the contents of this manual is owned by Adtech (Shenzhen) CNC Technology Co., LTD (hereinafter referred to as Adtech), without the permission of Adtech, any company or individual is not allowed to imitate, copy, reproduce or translate this manual. Our company makes no warranty, express representation or other imply regarding the contents of this manual. Adtech and its employees assume no responsibility for any direct or indirect information disclosure, benefit loss or business termination due to this manual or the products information described in it. In addition, the products and their information described in this manual are only for the purpose of reference, we reserve the right to amend the manual without prior notice. All Rights Reserved, Reprint Not Allowed .
Modification Date
2010/2/23
Instruction
Remarks: the meanings of the three numbers in the version number are as follows:
Notes: 1. This user manual is strictly emended and checked by ADTECH (SHENZHEN) CNC TECHNOLOGY CO., LTD, however, it is not guaranteed that the user manual has no any mistake or error. 2. ADTECH (SHENZHEN) CNC TECHNOLOGY CO., LTD commits itself to improve the product functions and the service quality consistently. Therefore, the company reserves the right of changing any products as described, any software program, and the content of the user manual, without prior notice.
Contents
1. OPERATION MODES AND DISPLAY INTERFACES .................................................................. 7 1.1. DESCRIPTION OF EDITING KEYPAD............................................................................................. 8 1.2. DISPLAY MENUS......................................................................................................................... 9 1.3. CNC PANEL ............................................................................................................................... 9 1.4. OPERATION MODES .................................................................................................................. 10 1.5. DISPLAY INTERFACE................................................................................................................. 11 1.5.1 Position interface .................................................................................................................. 13 1.5.2 Program display.................................................................................................................... 15 1.5.3 MDI...................................................................................................................................... 15 1.5.4 Program directory................................................................................................................. 16 1.5.5 KNIFE COMPENSATION INTERFACE ............................................................................. 16 1.5.6 aLARM INTERFACE .......................................................................................................... 17 1.5.7 sETTINGS INTERFACE...................................................................................................... 17 1.5.8 gRAPH INTERFACE ........................................................................................................... 18 1.5.9 GRAPH PARAMETERS ...................................................................................................... 18 1.5.10 gRAPH DISPLAY .............................................................................................................. 18 1.5.11 pARAMETER INTERFACE .............................................................................................. 19 1.5.12 Diagnosis INTERFACE ...................................................................................................... 19 SAFE OPERATION ...................................................................................................................... 21 2.1 HARDWARE OVERTRAVEL PROTECTION ..................................................................................... 21 2.2 SOFTWARE OVERTRAVEL PROTECTION ...................................................................................... 21 2.3 EMERGENCY OPERATION .......................................................................................................... 22 2.4 RESET ..................................................................................................................................... 22 2.5 EMERGENCY STOP.................................................................................................................... 22 2.6 FEEDING MAINTAINING ............................................................................................................ 22 2.7 CUTTING OFF POWER SUPPLY.................................................................................................... 22 2.8 TURNING OFF .......................................................................................................................... 23 MANUAL OPERATION............................................................................................................... 23 3.1 MANUAL FEEDING ................................................................................................................... 23 3.2 QUICK MOVING........................................................................................................................ 23 3.3 MANUAL MAGNIFICATION SELECTION ....................................................................................... 23 3.4 QUICK MAGNIFICATION SELECTION........................................................................................... 23 3.5 COORDINATES RESET ............................................................................................................... 24 3.5.1 Relative position reset........................................................................................................... 24 3.5.2 CNC coordinates reset .......................................................................................................... 24 3.6 OTHER MANUAL OPERATIONS ................................................................................................... 24 3.6.1 Main axis control.................................................................................................................. 24 3.6.2 Cooling liquid control........................................................................................................... 25 3.6.3 Chuck control ....................................................................................................................... 25 3.6.4 Manually replacing knife ...................................................................................................... 25 3.6.5 Regulation of main axis magnification.................................................................................. 25 SINGLE STEP/HANDWHEEL OPERATION .............................................................................. 25
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2.
3.
4.
CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test SINGLE STEP FEEDING .............................................................................................................. 25 INCREMENT SELECTION ............................................................................................................ 26 MOTION DIRECTION SELECTION................................................................................................ 26 HANDWHEEL FEEDING ............................................................................................................. 26 INCREMENT SELECTION ............................................................................................................ 27 MOTION AXIS AND DIRECTION SELECTION ................................................................................. 27 OTHER AVAILABLE OPERATIONS IN HANDWHEEL/SINGLE STEP MODE .......................................... 27 DESCRIPTION........................................................................................................................... 28
MDI OPERATION........................................................................................................................ 28 5.1. INPUT AND EXECUTION OF MDI INSTRUCTION WORDS ............................................................... 28 5.2. PARAMETER EDITING AND SETTING ........................................................................................... 29 PROGRAM EDITING AND MANAGEMENT ............................................................................ 29 6.1. CREATING PROGRAM................................................................................................................ 29 6.1.1 program content Input........................................................................................................... 29 6.1.2 Searching instructions words ................................................................................................ 30 6.1.3 Inserting instruction word ..................................................................................................... 33 6.1.4 Deleting instruction word...................................................................................................... 33 6.2. DELETING PROGRAM................................................................................................................ 34 6.2.1 Deleting single program........................................................................................................ 34 6.2.2 Deleting lines from the program ........................................................................................... 34 6.2.3 Deleting all programs............................................................................................................ 35 6.3. PROGRAM SELECTION .............................................................................................................. 35 6.3.1 Searching.............................................................................................................................. 36 6.3.2 Scanning............................................................................................................................... 36 6.3.3 Cursor confirmation.............................................................................................................. 36 6.4. PROGRAM MANAGEMENT ......................................................................................................... 36 6.4.1 Program directory................................................................................................................. 36 6.4.2 locking Program ................................................................................................................... 36 KNIFE BIAS AND ALIGNMENT ................................................................................................ 37 7.1. FIXED KNIFE ALIGNMENT ......................................................................................................... 37 7.2. TEST CUTTING KNIFE ALIGNMENT ............................................................................................. 38 7.3. KNIFE ALIGNMENT IN MECHANICAL ORIGIN .............................................................................. 39 7.4. EDITING THE BIAS VALUE ......................................................................................................... 41 7.4.1 Absolute value input of knife compensation.......................................................................... 42 7.4.2 Increment input of knife compensation ................................................................................. 42 AUTOMATIC OPERATION......................................................................................................... 42 8.1 AUTOMATIC RUNNING .................................................................................................................. 42 8.1.1 Automatic running start......................................................................................................... 43 8.1.2 Automatic running stop......................................................................................................... 43 8.1.3 Automatic running in any section.......................................................................................... 44 8.1.4 Feeding magnification regulation.......................................................................................... 44 8.1.5 Main axis speed regulation ................................................................................................... 45 8.1.6 Single section running .......................................................................................................... 45 8.1.7 Program section skip............................................................................................................. 46 8.1.8 Other operations ................................................................................................................... 46
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6.
7.
8.
9.
CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test ORIGIN OPERATION.................................................................................................................. 46 9.1. PROGRAM ORIGIN .................................................................................................................... 46 9.1.1 Program origin...................................................................................................................... 46 9.1.2 Procedures of program origin................................................................................................ 46 9.2. MECHANICAL ORIGIN............................................................................................................... 47 9.2.1 Procedures of mechanical origin ........................................................................................... 47 9.2.2 Other operations in origin mode............................................................................................ 48
10. DATA SETTING AND SAVING................................................................................................ 48 10.1. DATA SETTING ...................................................................................................................... 48 10.1.1 Options in setting interface ................................................................................................. 48 10.1.2 Settings in graph interface................................................................................................... 49 10.1.3 System/diagnosis parameters setting ................................................................................... 49 11. FILE MANAGER...................................................................................................................... 50 11.1. CONNECTING USB DISK TO PC ............................................................................................. 50 12. PROCESSING EXAMPLES...................................................................................................... 53 12.1. CREATING NEW PROGRAMS ................................................................................................... 54 12.2. PROGRAM VERIFICATION ...................................................................................................... 56 12.2.1 Graph parameter setting ...................................................................................................... 56 12.2.2 Program running ................................................................................................................. 58 13. CONNECTION TEST ............................................................................................................... 59 13.1. MOTOR DRIVE CONNECTION TEST ......................................................................................... 61 13.1.1 Connection of motor, drive and controller ........................................................................... 62 13.1.2 Setting and calculation of eletronic gear ratio...................................................................... 64 13.1.3 Acceleration/deceleration features adjustment ..................................................................... 65 13.1.4 Troubleshooting for motor drive ......................................................................................... 65 13.2. HARD LIMIT FUNCTION ......................................................................................................... 66 13.2.1 Enabling hard limit function ............................................................................................... 66 13.2.2 Troubleshooting for hard limit ............................................................................................ 67 13.3. MECHANICAL ORIGIN ADJUSTMENT ....................................................................................... 67 13.3.1 Origin parameter setting...................................................................................................... 67 13.3.2 Troubleshooting for mechanical origin................................................................................ 69 13.4. REVERSE CLEARANCE COMPENSATION .................................................................................. 69 13.5. DRIVE PROTECTION SETTINGS AND CHECKING ....................................................................... 70 13.6. MAIN AXIS ENCODER ............................................................................................................ 71 13.6.1 Troubleshooting for main axis encoder................................................................................ 71 13.7. MAIN AXIS CONTROL ............................................................................................................ 72 13.7.1 Wiring diagram................................................................................................................... 72 13.7.2 Main axis parameter setting ................................................................................................ 74 13.7.3 Calibration of analog voltage .............................................................................................. 74 13.7.4 Time sequence and V/S characteristic diagram.................................................................... 75 13.7.5 table of Multi-section speed regulation states ...................................................................... 75 13.7.6 Troubleshooting for main axis control................................................................................. 76 13.8. CHUCK CONTROL ................................................................................................................. 76 13.8.1 Wiring diagram................................................................................................................... 76 13.8.2 Chuck parameter setting...................................................................................................... 76
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test 13.8.3 Troubleshooting for chuck control ...................................................................................... 77 13.9. TAILSTOCK CONTROL ........................................................................................................... 78 13.9.1 Tailstock wiring diagram..................................................................................................... 78 13.9.2 Parameter settings............................................................................................................... 79 13.10. KNIFE REPLACING CONTROL ................................................................................................. 79 13.10.1 Wiring diagram of electric knife rack ................................................................................ 79 13.10.2 Knife replacing parameter setting...................................................................................... 81 13.10.3 Troubleshooting for knife replacing .................................................................................. 81 13.11. HANDHELD BOX AND ADDITIONAL PANEL INTERFACE XS7 ..................................................... 81 13.11.1 Internal wiring diagram of the handheld box ..................................................................... 81 13.11.2 Pin function of handheld box interfaces............................................................................. 81 13.11.3 Wiring diagram of additional panel ................................................................................... 83 13.11.4 Precautions and parameter setting for handheld box .......................................................... 83 13.11.5 Troubleshooting for handheld box..................................................................................... 83 13.12. WIRING DIAGRAM OF COOLING AND LUBRICATION CONTROL .................................................. 84 13.13. WIRING DIAGRAM OF WORKING INDICATORS ......................................................................... 84 13.14. PROGRAMMABLE I/O PORT ................................................................................................... 85 13.14.1 Wiring diagram of programable i/o port ............................................................................ 85 13.14.2 Wiring diagram of programable input and certain control ports ......................................... 85 13.15. WIRING DIAGRAM OF MAIN POWER SUPPLY ........................................................................... 86 13.16. SYSTEM PARAMETERS TABLE ................................................................................................ 87 13.17. ALARM INFO REFERENCE TABLE ............................................................................................ 90 13.18. MAIN FUNCTIONS AND PARAMETERS REFERENCE TABLE ......................................................... 93 13.19. SYSTEM WIRING DIAGRAMS .................................................................................................. 95 13.19.1 Servo drive wiring diagram............................................................................................... 95 13.19.2 Step drive wiring diagram ................................................................................................. 95 13.19.3 Main axis encoder wiring diagram .................................................................................... 96 13.19.4 Hard limit wiring diagram................................................................................................. 97 13.19.5 Mechanical origin wiring diagram..................................................................................... 97 13.19.6 Main axis control wiring diagram...................................................................................... 98 13.19.7 Chuck control wiring diagram........................................................................................... 99 13.19.8 Tailstock control wiring diagram..................................................................................... 100 13.19.9 Electric knife rack wiring diagram .................................................................................. 101 13.19.10 Additional panel wiring diagram ................................................................................... 103 13.19.11 Cooling and lubrication wiring diagram ........................................................................ 103 13.19.12 Power supply wiring diagram........................................................................................ 104 13.19.13 Indicator wiring diagram............................................................................................... 105 13.19.14 Installation dimensions ................................................................................................. 105
Product appearance
The appearance and deployment of the operation panel are shown below:
Parameter settings 00004 N0000 1. Multiplying ratio of 1 instructions in X axis 2. Frequency division coefficient 1 of instructions in X axis 3. Multiplying ratio of 1 instructions in Z axis 4. Frequency division coefficient 1 of instructions in Z axis 5. Feeding speed 4000 (mm/min) 6. Start speed of feeding 300 (mm/min) 7. Feeding acceleration time 200 (ms/min) System parameters Page 1 Multiplying ratio of instructions in X axis S0000 T0100 Manual mode
Position
Program
Knife compensation
Edit Auto
Main axis/negative
Manual
MDI
Reset
Single step
Skip
Settings
Parameters Diagnosis
Pause
Magnification
Reset
State indicators
To indicate the manual mode
Edit
Manual
Auto
Single step
Single segment
Reset
Address keys
Input address
Number keys
Input numbers The number keys 8, 2, 6 and 4 are X-, X+, Zand Z+ in manual mode and single step mode respectively; the direction key 5 is the quick switch in manual mode
Minus sign key Radix point Cancel Cancel key Editing keys
Input the minus sign Input radix point Clear the contents in input line Insert or delete programs or fields while editing
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Insert/Delete
CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test EOB key Input the end symbol of program segment, or edit the option Control the moving of cursor in program editing mode and parameter interface Adjust the feeding and magnification quickly in auto mode Single step mode: Adjust the increment in single step Turn pages in same display mode
Settings
Parameters
Diagnosis
Magnification
CNC42 20 Feeding rate / Rapid magnification / Main axis magnification switch key Manual knife replacing key Switch key of lubricant Switch key of cooling liquid Main axis control key
Ma c hi ne Too l Op e rat io n a nd Test Automatic or manual feeding speed / fast-moving magnification / Main axis speed regulation
Knife replacing Chuck Cooling Main axis/positive Main axis/stop Main axis/negative
Replace the knife manually Lubricant on/off of the machine tool Cooling liquid on/off Forward rotating of main axis Main axis stops Reverse rotating of main axis
Manual key
feeding
X axis and Z axis move in positive/negative direction in manual and single step operation modes
Quick switch
Switch quick/manual feeding speed Switch running state between single section and continuous for the program; if single section is valid, the single section indicator is on. Enter editing mode Enter auto mode Enter MDI operation mode, enter program reset operation mode
Single section
Single switch
section
Editing mode selection key Auto mode selection key Data input mode selection key
Mechanical reset Enter mechanical reset mode mode selection key Single step/ handwheel mode selection key Manual mode selection key Switch single step/ handwheel mode Enter manual operation mode
CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test In auto mode, the program runs automatically l MDI operation mode In MDI mode, input the parameters, and insert and execute instruction segment. l Mechanical reset operation mode In mechanical reset mode, perform the mechanical reset operation for X axis and Z axis respectively l Handwheel/single step operation mode In single step/handwheel feeding mode, the system moves in selected increment l Manual operation mode In manual mode, perform the operations such as manual feeding, manual speed, feeding rate regulation, quick rate regulation, main axis start/stop, cooling liquid switch, lubricant switch and manual knife switch. l Program reset operation mode In program reset mode, perform the program reset operation for X axis and Z axis respectively.
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Absolute position
Position
Position interface
Program
Program interface
value
Parameter switch Settings interface Setting s Graph interface Graph display File manager
Graph parameters
Input point state Handheld box and main axis encoder test
Diagnosis
Diagnosis interface
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comprehensive and position/program pages. You can press the Up/Down key view.
to
Absolute coordinates
The X coordinate and Z coordinate are the absolute position of the knife in current work piece coordinates system, which is specified byG50. Current position (absolute coordinates)
Programming speed: the speed specified by F code in the program (unit: mm/min). Actual speed: the actual processing speed (unit: mm/min) after the magnification has been adjusted in the actual processing. Feeding magnification: the current feeding magnification Quick magnification: the current quick magnification G function code: current valid G code processing pieces in Group 01 and 03: when the program has executed M30, the processing pieces are increased by 1. Cutting time: the cumulative time when the program and MDI are running; the time format is: Hour: Minute: Second. The cutting time is 0 when the system is electrified. T: current tool number S: current main axis rotation speed Note: The main axis encoder is necessary to display the actual rotation of the main axis.
Relative coordinates
The U coordinate and W coordinate, which are 0 when the system is electrified, are the relative coordinates of current position relative to the reference point. In manual mode, press the letter key or , and the U or W flashes in the page; press the Cancel key W coordinate. to reset the U or
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Comprehensive coordinates
In comprehensive position page, relative coordinates, absolute coordinates, machine tool coordinates and remaining movement are displayed at the same time. The value of machine tool coordinates is the coordinates of current position in machine tool coordinates, which is created through mechanical reset. The remaining movement is the difference between the target coordinates of program section or MDI instruction and the current absolute coordinates. The page follows: Current position (machine tool coordinates) (Absolute coordinates)
(Relative coordinates)
(Remaining movement)
Position/program
In position/program page, the absolute coordinates and relative coordinates of current position and program line of current program are displayed at the same time. When the program is running, the displayed program line refreshes dynamically. Current position (machine tool coordinates) (Absolute coordinates)
Program interface
Press the Program key to enter the interface, which consists of program, MDI and program to view.
1.5.3 MDI
In MDI page, display the current instruction states of G, M, S, T and F, and display the contents of current program section in auto and MDI modes. Program section value Mode state value
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16
Settings interface
The Setting key
is composite, and you can press it repeatedly to switch the setting/graph interface.
Manual mode Fig. 1-3-12 Parameter switch: when the parameter switch is on, you can edit the parameters; when it is off, you cant edit; press the key to switch the state in MDI mode Program switch: when the program switch is on, you can edit the program; when it is off, you cant edit; press the key to switch the state in MDI mode
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data parameters. You can press the Up/Down key to view. In parameters display page, the prompt line of parameter contents displays the contents of the parameter that the cursor points to. The parameters can be edited in MDI mode. Input the target parameter number and press the EOB key to go to the specified parameters. Parameter settings 1. Axis X instruction magnification 2. Axis X instruction frequency conversion coefficient 3. Axis Z instruction magnification 4. Axis Z instruction frequency conversion coefficient 5. Feeding speed 6. Start feeding speed 7. Feeding acceleration time System parameters Page 1 1. Axis X instruction magnification
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Handwheel
20
2. Safe operation
XS5 interface
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2.4 Reset
When the system output or coordinates action is abnormal, press the Reset key to reset the system: 1. The motion of all axes stops; 2. M, S function output is invalid (it is possible to set whether disable main axis positive/negative rotation, lubricant and cooling signals automatically after pressing the Reset key 3. Automatic running stops, and mode function and state maintain. );
3. Manual operation
Press the Manual key to enter the manual operation mode, in which you can perform operations like manual feeding and main axis control.
/ key when the quick magnification appears in the lower left corner of the position interface to decrease or increase the manual feeding magnification, which contains 16 levels and 10% each level.
CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test mode of quick moving magnification; when the quick magnification appears in the lower left corner of the position interface, press the and key to decrease or increase the manual quick moving magnification respectively, and switch among F0, 25%, 50% and 100%. Press the key once to increase the quick moving magnification by one grade, until 100%;
Press the key once to decrease the quick moving magnification by one grade, until F0 Note 1: system parameters 10 and 11 set the quick moving speeds of axis X and axis Z respectively; actual quick moving speed of axis X = the value set by system parameter 10 * quick magnification; actual quick moving speed of axis Z = the value set by system parameter 11 * quick magnification Note 2: the quick moving can be adjusted only in position interface and manual mode. Note 3: the quick magnification is valid in the following conditions (1) G00 orientation (2) Quick moving in fixed circle (3) Quick moving at G28 (4) Manual quick moving (5) Quick moving of returning to mechanical origin manually: e.g. if the speed of quick moving is 6m/min and the magnification is 50%, then, the speed is 3m/min.
2) Press the key to make the U flash in the page, and then press the Cancel key clear the relative coordinates of axis X; key to make the W flash in the page, and then press the Cancel key 3) Press the clear the relative coordinates of axis Z;
to
to
At the same time, press the Cancel key tool coordinates of axis Z
CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test Main axis/stop: In manual operation mode, press this key, and the main axis stops rotating; Main axis/reverse: In manual operation mode, press this key, and the main axis rotates in reverse direction.
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See the description in Section 1.1, and the value varies according to the selection
G code: Processing pieces: Cutting time: Single step mode Fig. 4-1-1
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Handwheel increment:
G code: Current axis: Processing pieces: Cutting time: Handwheel mode Fig. 4-1-2
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4.8. Description
1. See the table below for the relationship between handwheel scale and machine tool motion: Motion of every scale on the handwheel Handwheel 0.001 0.01 0.1 increment Specified value 0.001mm 0.01mm 0.1mm of coordinates 2. The rotation speed of the handwheel cant exceed 3r/s, or else, the scale and motion wont be consistent; 3. If the system uses step motor, the rotation speed of the handwheel shouldnt exceed 5r/s or the single step position that can disable 0.1mm and 1mm.
5. MDI operation
In MDI operation mode, you can set the parameters, input and execute instruction words.
C. Type X50 in sequence and then press the Insert key, type G50 and press the Insert key, type Z100 and press the Insert key Reset key (if any error appears when type the fields, please press the
to clear all contents, and then type new data). As in the figure below:
(Program section value) (Mode state value)
instruction words. During running, you can press the Pause key, Reset key Emergency stop button to stop the running of MDI instruction words. PDF "pdfFactory Pro" www.fineprint.com.cn
CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test Note: Subroutine call instruction (M98 P___ ;) and composite cutting cycle instruction (G70, G71, G72, G73, G74, G75, G76, etc.) are invalid in MDI.
2) Press the Program key to enter the program page, and press the select program editing interface if necessary.
Program
3) Type the address key O and number key 0001 in sequence (to create program O0001). 4) Press the Insert key to create new program, as shown in the figure:
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5) To edit the program content, please input the address and then the number (If the program section contains several instruction words, please input all instruction words in the above mentioned method), and then press the Insert key to complete the input of the program
section. (If the input buffer contains the input characters, press the key at the line end to insert the data in buffer and start a new line. If it is in the line, please edit current instructions.) Press the key and the cursor goes to the program section in next line.
Press the key once, the cursor moves to next instruction word; press and hold the the cursor moves downwards by instruction word consecutively; press the Up/Down key, the cursor moves in opposite direction.
Program
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test 2) Press the the first page, the the key to display the previous page of the program (when the program is in key is invalid), the cursor locates the start of previous page; press
key to display the next page of the program (when the program is in the first page,
the key is invalid), the cursor locates the start of next page. Press and hold the key to turn pages consecutively. Searching (instruction word): search for specified instruction word upwards or downwards from the cursor position. The current position of the cursor is N0030, now move the cursor to Z9.5;
Program
The operation method follows: 1) Press the address key 2) Press the , number key and in sequence;
key and the system starts searching downwards; after that, the cursor locates key to search upwards, the system cant find instruction word
Note: to search for Z9.5, please input Z9.5 exactly; if you input Z9.50 only, the system cant find Z9.5. Searching (address): search specified address upwards or downwards starting from current position. The current position of the cursor is N0030, now move the cursor to Z14;
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The operation follows: 1) Input Z14. 2) Press the key and the system starts searching downwards; after that, the cursor locates key to search upwards, the system cant find instruction word
Not searched! Data= Editing mode To return to the start of the program
Method 1 In editing mode and program display page, press the Reset key start of the program. Method 2: Searching (a) Select the editing mode; (b) Press the Program key (c) Type address key number 5);
to enter the program display interface; and number key (the current program is
(d) Press the key and the cursor returns to the start of the program Method 3: scanning (1) Select the editing mode to enter the program display interface;
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test (2) Press the address key the program. and then the key, and the cursor returns to the start of
, as shown below:
to delete G01 (the instruction word that current cursor points at), as
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Data= Manual mode 3) To delete the characters in input buffer: If X1000 has been input in the input buffer, press the Delete key to delete the last character, then, the character in the input buffer is X100, and press again to input X10.
in sequence,
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2) Input characters
and
to delete from the cursor to the line end, as in the figure below: Program
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6.3.1 SEARCHING
Take O0005 for an example, (a) Select the editing mode; (b) Press the Program key (c) Type the address key sequence; to enter program display interface; and number keys in
(d) Press the key, and the searched programs appear on the L D (the system alarms if the C program doesnt exist).
6.3.2 SCANNING
(a) Select the editing mode; (b) Press the Program (c) Press the address key key to enter the program display interface; ;
key to display next program; (d) Press the (e) Repeat step c and d to display the saved programs one by one.
3) Press the
or
press the
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test Setting Parameter switch (W): Program switch (H): OFF OFF ON ON
Manual mode
To set the program switch: Press Settings to switch to setting switch page, and press the switch the state to off.
key to
Fig. A
Fig. B
1) Select a knife as the reference, and set the bias number in the knife to 0 (e.g. T0100, T0300); 2) Locate the tip of the reference knife to a point (the knife alignment point), and measure the diameter "" (suppose =10), as Fig. A;
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and Insert key in sequence, and then press the Start and Z to the value to work piece coordinates 4) Clear the relative coordinates (U, W) (press the Position Cancel Cancel );
4) Press the Knife compensation key to enter the bias interface, press the cursor to select the corresponding bias number of the reference knife; 5) Press the address key of reference knife to 0; , number key , and then press the Insert key
key to move
6) Press the address key , number key , and then press the Insert key to set the bias of axis Z of reference knife to 0; 7) Move the knife to safe position, select another knife (set the bias number in the knife to 0) and move to the alignment point, as Fig. B; 8) Press the knife compensation the knife; key, and move the cursor to select the corresponding bias number of
9) Press the address key and then press the Insert key X to the corresponding bias number; 10) Press the address key and then press the Insert key Z to the corresponding bias number; 11) Repeat step 7~10 to align other knives.
1) Select knife 1 as the reference to make the knife cut along surface A; 2) Take out the knife along axis X when axis Z is still, and stop the rotation of main axis;
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3) Press the Knife compensation key to enter the bias interface, and press the move the cursor and select bias number (the bias number corresponding to this knife is 101); 4) Type the address key , number key to 0 and the current coordinates are Z0; 5) Cut along surface B with the knife; 7) Measure the diameter "" (suppose =15 ; to enter the bias interface, and press the 8) Press the Knife compensation key move the cursor and select bias number (the bias number corresponding to this knife is 101); and Insert
key to
6) Take out the knife along axis Z when axis X is still, and stop the rotation of main axis;
key to
9) Type the address key , number key , direction Z to 0 and the current coordinates are X15; 10) Move the knife to a safe position and change the knife; 11) Cut along the surface A in manual mode;
and Insert
12) Take out the knife along axis X when axis Z is still, and stop the rotation of main axis; 13) Measure the distance "" between surface A and origin of work piece coordinates (suppose =1) 14) 1 Press the Knife compensation key to enter the bias interface, and press the move the cursor and select bias number (the bias number corresponding to this knife is +100); , symbol key 15) Press the address key to set the knife bias of axis Z; 16) Cut along the surface B in manual mode; 18) Measure distance "" (suppose =10 ; , number key and Insert key to
key in sequence
17) Take out the knife along axis Z when axis X is still, and stop the rotation of main axis;
19) Press the knife compensation to enter the bias interface, and press the move the cursor to select bias number (the bias number corresponding to this knife is +100);
and
key to
, number key 20) Type the address key of axis X; 21) Repeat step 10-20 to align other knives.
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Surface B Surface A
1) Press the Reset key to enter mechanical reset mode and return the two axes to the mechanical origin; 2) Select a knife and set the bias number in the knife to 0 (e.g. T0100, T0300) 3) Cut along surface A with the knife;
4) Press the Knife compensation key move the cursor and select bias number;
key to
, number key 5) Press the address key 6) Cut along surface B with the knife; 8) Measure distance "" (suppose =15 ;
and Insert
7) Take out the knife along axis Z when axis X is still, and stop the rotation of main axis;
9) Press the Knife compensation key move the cursor and select bias number;
key to
10) Press the address key , number key 11) Move the knife to safe position;
and Insert
12) Change another knife and set the bias number to 0(e.g.T0100, T0300 ; Surface B1 Surface A1
13) Cut along surface A1 with the knife; 14) Take out the knife along axis X when axis Z is still, and stop the rotation of main axis; measure the distance "" (suppose=1) between surface A1 and work piece origin;
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, symbol key
, number key
to set the
17) Cut along surface B1 with the knife; 18) Take out the knife along axis Z when axis X is still, and stop the rotation of main axis; 19) Measure distance "1" (suppose 1=10 ; 20) Press the Knife compensation key to enter the bias interface, and then press the key to move cursor and select the bias number;
21) Press the address key , number key 22) Move the knife to safe position; 23) Repeat step 14-22 to align other knives.
and Insert
Note 1: the machine tool should have mechanical origin switch to perform the knife alignment operation in mechanical origin. Note 2: after knife alignment in mechanical origin, it is not possible to execute the G50 instruction to set the coordinates of the work piece As shown below:
Data Position:
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Press the key to display the compensation on the LCD. For example: Input -20 in the X value of bias number T0202, and the operation follows: In the MDI mode, type X-20 and then press the
Knife compensation parameters S/N
8. Automatic operation
8.1 Automatic running
Select the program with searching or scanning method l Searching (take searching program O0001 as an example) A. Select the Auto mode; B. Press the Program C. Press the address key key to enter the program page; and number keys 0, 0, 0, 1 in sequence;
D. Press the key to display the searched programs on the LCD (the system alarms if the program doesnt exist). l Scanning
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test A. Select the Auto mode; B. Press the Program C. Press the address key key to enter the program display interface; ;
D. Press the key to display the next program; E. Repeat step 3 and 4 to display the saved programs in sequence.
key and then press the Start B. Press the Reset program run automatically.
A. During automatic running, press the Pause key or external pause key, and the machine tool is in the following states: (1) The machine tool feeding decelerates and stops; (2) The timing pauses when the G04 instruction executes; (3) The mode functions and states are saved; (4) Press the Start key to resume the running of the program.
B. Press the Reset key (1) The motion of all axes stops; (2) The output of M and S function is invalid (may be set in the parameters that whether turn off main axis positive/negative rotation, lubrication and cooling signals after pressing the Reset key ); (3) The automatic running stops and the mode function and state maintain. C. Press emergency stop button When the machine tool is running, press the emergency stop button (if external emergency stop signal is valid) if there is any danger or emergency, and the system enters the emergency stop state immediately. At this moment, the machine tool stops moving immediately, and all outputs (e.g. main axis rotation, cooling liquid) are turned off. Release the button to relieve the alarm, and the system enters reset state. Note 1: Please make sure that the failure has been eliminated before relieving the emergency stop alarm; Note 2: Before turning on/off the machine, press the emergency stop button to reduce the electric impact to the equipment;
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test Note 3: After relieving the alarm, please re-execute the mechanical reset operation to ensure the accuracy of the coordinates (if the machine tool doesnt have mechanical origin, do not perform this operation); Note 4: The function is valid only when the value is set to 1.
to enter the
program display page, and then press the Auto key to enter the auto mode; B. Move the cursor to the program section to start running (for example, to start running from N0050, move the cursor to instruction word N0050);
Program
C. Move the knife to the end position after the previous program section of the current program section has run. D. If the current mode state isnt consistent to the mode state before running this program section, please perform the corresponding mode function and state; E. Press the Start key to start the program.
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test l Feeding magnification regulation Press the Magnification key magnification in 16 levels. Press the and the or key to adjust the feeding
key once to increase the feeding magnification by one level, until 150%;
Press the key once to decrease the feeding magnification by one level, until 0; Note 1: the value specified by F in feeding magnification regulation program Note 2: actual feeding speed = speed specified by F feeding magnification l Quick magnification regulation During automatic running, press the magnification key regulation mode. Press the Press the Press the or to switch to quick magnification
key once to increase the feeding magnification by one level, until 100%; key once to decrease the feeding magnification by one level, until F0.
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test In auto mode, press the Single section key to light the single section running indicator in state area, indicating that the single section running is selected; or enter the diagnosis interface machine tool panel page, and press the number key to select on for single program section. During single section running, the system executes the current program section and then stops running; press the Start key, the system executes next program section and then stops running; repeat the operation until the running completes. Note 1: for instruction G8, the single section stops in the center point; Note 2: while execute fixed circle G90, G92, G94, G70~G76 instructions, refer to Programming Description for the state of single section
9. Origin operation
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B. Press the or key to select the program origin of axis X or Z; Note 1: the axis X and axis Z cant return to program origin at the same time; Note 2: after the program origin operation, the system cancels the knife length compensation.
Axis X fast origin speed: Axis Z fast origin speed: Axis X slow origin speed: Axis Z slow origin speed:
B. Press the or key to select the mechanical origin of axis X or Z; C. The machine tool moves in mechanical origin direction, returns to mechanical origin after signal test, and then the axis stops moving. Note 1: If the machine tool doesnt have mechanical origin, do not perform the mechanical origin. To stop the axis motion in the origin process, press the Reset key button. PDF "pdfFactory Pro" www.fineprint.com.cn or emergency stop
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test Note 2: after the mechanical origin operation, the system cancels the knife length compensation.
In addition, in program origin/mechanical origin, you can also adjust the main axis magnification, quick magnification and feeding magnification.
Manual mode
B. Press the key to switch the parameter state, and press the key to switch the program state Note: you can edit the parameters only when the parameter switch is on, and edit the programs only when the program switch is on.
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/ key to select desired parameter number C. Press the D. Input new parameter value; E. Press the key to input and display the parameter value;
F. After setting all parameters, please turn off the parameter switch; The setting method of diagnosis parameters is same to the setting of system parameters.
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File manager The controller is simulated to a common USB disk, and you can perform the operations. Press the key to select and highlight the function, and press the EOB key to enter the function.
Connecting USB disk to PC is selected by default, press the EOB to connect, and the USB connection icon appears in the system tray of the PC. Open the USB disk to have two folders: ADT and PRG, as in the figure below:
The ADT folder is used to save the update of machine tool. It is empty by default. To update, copy the program ADTROM.BIN to this folder and then select the update program in the BISO interface.
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test The PRG folder is used to save the processing file of the user (G code). To update the system, press the direction keys in File manager interface to move to Read external USB disk, insert the USB disk with the update program file, and then press the EOB key. Settings File manager Connect USB disk to PC The controller reads external Read external USB disk USB disk. The controller is Storage IC test used as a PC to view the files Restart system in external USB disk. You can delete, copy and update the system, import/export processing files and parameter files, and back up system programs. Press the # key to switch the function menu. Open the USB disk to display the file names in the directory and the sub-directories, as in the figure below: Current directory: usb:\
Previous Next (EOB) Enter directory (N) Create file (D)Delete file (CAN)Back
Press the Up/Down key to select files and sub-directory, for example, select ADTROM.BIN, press the Down key for three times, and the ADTROM.BIN is in reverse video, as in the figure below: Current directory: usb:\
Previous Next Show file (N) Create file (D)Delete file (CAN)Back
Press the # key to switch the menu, press the Up/Down key to select a function, and then press the EOB key to execute the function, as in the figure below:
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Import processing files Export processing files Import system parameters Export system parameters System program backup System program update
Press the Down key to move the cursor to System update, and press the EOB key to update the system program, as in the figure below: Current directory: usb:\
Import processing files Export processing files Import system parameters Export system parameters System program backup System program update
The system restarts after transmitting the file; if the system is started with the USB disk, the new program is executed after restarted, otherwise, please update the program in BISO.
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Programming
According to the mechanical processing and the instruction description in this manual, create a coordinates system of work piece as shown in Fig. 3-12-1, and the programming follows: O0001 M03S2000 T0101 N0010G0X40Z10 N0020G71U1R1 N0030G71P40Q140U0.2W1F800 N0040G0X5Z0 N0050G1Z-5 N0060G02X10Z-7.5R2.5 N0070G1Z-9.5 N0080G03X15Z-12R2.5 N0090G1Z-14 N0100G1X21Z-17 N0110G1X26 N0120Z-22 N0130X30 N0140Z-27 T0202 G70P40Q140 M30 %
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key to select program directory, as shown below: Program directory O0004 N0000 Version:V2009.02.25 Hardware version:Ver1.4 Current work area:0000 Library version:Ver1.2 Saved programs:12 Remaining: 9988 Used storage: 2812 Remaining: 2094340
Manual mode View software version, saved programs, storage space, program names, and select processing program.
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Input according to the above program to edit the program, and the homepage of the program after editing follows:
Program
Press the
or
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key to enter graph parameter page, as shown below: Graph parameters Coordinates selection Scaling + Graph center X (work piece coordinates) Graph center Z (work piece coordinates) Maximum X Minimum X Maximum Z Minimum Z X origin bias of graph Z origin bias of graph Data =
Manual mode
Press the
or
key to move the cursor and select desired options of graph parameters.
For example, to set Maximum X, press the / key to move the cursor to parameter Maximum X (actual size of the semifinished product is 135mm and the input value should be higher than 135m; 150 is set here), type , , key to have the page below: Graph parameters Coordinates selection Scaling + Graph center X (work piece coordinates) Graph center Z (work piece coordinates) Maximum X Minimum X Maximum Z Minimum Z X origin bias of graph Z origin bias of graph Data = MDI mode Graph parameters
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test Set other data in the above method and the page after setting follows:
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test Graph parameters Coordinates selection Scaling + Graph center X (work piece coordinates) Graph center Z (work piece coordinates) Maximum X Minimum X Maximum Z Minimum Z X origin bias of graph Z origin bias of graph Data = Auto mode
to turn to the graph track page, press to start drawing, and press the Start key to make the program run automatically. You can verify the program by displaying the graph track, as shown below:
Graph
Auto mode
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Serial port
PC
Connection diagram of machine tool XS1X axis: 15-core D-pin socket is connected to step motor drive or digital AC servo drive XS2 Z axis: 15-core D-pin socket is connected to step motor drive or digital AC servo drive XS3 USB communication updates software and transmits programs for the PC and CNC4220 controller XS4 main axis encoder: 15-core D-pin socket is connected to main axis encoder. XS5 input interface: 25-core D-pin socket limits each axis and input signals for other switching quantities. XS6 output interface: 25-core D-pin socket outputs signals for switching quantities. XS7 handheld box: 15-core D-pin socket is connected to the handheld box. XS8 main axis: 9-core D-pin socket is connected to the main axis frequency inverter XS9 serial port: 9-core D-pin socket can import/export processing files. XS10 USB disk: external USB interface can import/export processing files, system configuration files, or update programs with external USB disk. CNC4220 controller uses 24V DC power supply, and the internal power consumption is about 5W.
Installation precautions
Installation condition of electric cabinet When design the electric cabinet, the distance between the rear cover and the case should be at least 20cm. It should be noted that the temperature difference between the inside and outside of the cabinet shouldnt exceed 10 when the temperature inside the electric cabinet rises. The electric cabinet should be able to prevent the entering of dust, cooling liquid and organic solution. The electric cabinet should be equipped with fan to ensure internal air circulation. The display panel should be installed at the place that the cooling liquid cant spray on.
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test When design the electric cabinet, please reduce the external electrical interference to avoid affecting the system. To avoid interference When the system is designed, we have taken measures to shield space electromagnetism radiation, absorb impact current, filter power clutter and other measures to avoid interference. It can prevent the external interference to the system to a certain extent. To ensure that the system works stably, please take the following measures when install the system: 1: Keep the machine tool away from equipment that may cause interference (e.g. frequency inverter, AC contactor, static generator, high voltage generator and section device of power lines). At the same time, connect the switching power supply to the filter separately to improve the interference resistance of the machine tool (see Fig. 1-4). 2: To supply power for the system through isolation transformer, the machine tool installed with the system should be grounded, and machine tool and the drive should be connected to separate earth wire from the connection point. 3: Interference suppression: connect RC loop in parallel on both ends of AC coil (0.01F, 100~200, as in Fig. 1-5); approach to inductive load when install RC loop; install reverse parallel freewheeling diode on both ends of DC coil (Fig. 1-6); connect surge absorber in parallel at the winding end of the AC motor (Fig. 1-7).
Filter
Fig. 1-5
Surge absorber
5: To reduce the interference between machine tool signal cable and strong electricity cable, please follow the rules below for wiring: Cable type Group Wiring requirement AC power cord A AC coil AC contactor B DC coil (24VDC) Bind cables in group B separately from those in group A, or shield the cables in group B; keep
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Bind cables in group A separately from those in group B and C, keep at least 10cm between each other, or shield the cables in group A
DC relay (24VDC) Cable between the system and strong electricity cabinet Cable between the system and machine tool Cable between the system and servo drive Position cable C feedback
CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test the cables in group B as far as possible from group C
Bind cables in group C separately from those in group A, or shield the cables in group C; keep at least 10cm between the cables in group B and group C and use twisted pair cables
Wire No. 1 2 3 4 5 6 7 8 9 10
Defi niti on symb ol PU+ PUDR+ DRALM ALR ECZ+ ECZPUCOM 24V+
XS1 a nd XS2 i nt erfa c e F unct i on P uls e si gna l + P uls e si gna l Direct i on si gna l + Direct i on si gna l Ser vo a la r m si gna l a xis X: IN34, a xis Y: IN35 Ala r m c lea ri ng a xis X: O UT24, a xis Y: OUT25 Enc oder pha se Z i nput + Enc oder pha se Z i nput Positive end of internal 5V power supply; cant connect to external power supply (drive for single end input) Int erna l 24 V power s uppl y, c onnec te d dire ctl y t o t he 24 V power suppl y of t he c ontroll er
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Servo motor drive Note: Never connect any two of PU+, PU-, DR+ and DR-; otherwise, the pulse interface will be damaged. 2. Single end mode: This mode is suitable for the step drives that the anodes of pulse and direction are connected together.
Step motor drive Note: It isnt suitable for the step drives that the cathodes of pulse and direction are connected together. Certain drives connect the anodes of optical coupling input, i.e. the common anode connection. At this moment, connect the wires according to the figure below and do not connect PU+ and DR+ together; otherwise, the pulse interface will be damaged. The common cathode connection, i.e. connecting the cathodes of optical coupling input together, isnt suitable for machine tool controller. Please note that the PU_COM is only for the non-differential connection of the drive pulse; otherwise, the controller will be damaged.
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Power input
XS1 interface
XS1 interface
Drive
Drive
Encoder
Example 2: Connection of CNC4220 and SGDM drive Example 1: Connection of CNC4220 and JaBao QS5 drive
Encoder
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XS1 interface
XS1 interface
Axis X servo motor drive Axis X servo motor Example 3: Connection of CNC4220 and Q2BYG1106M step drive Axis X servo motor
Motor drive test 13.1.2 SETTING AND CALCULATION OF ELETRONIC GEAR RATIO
After connection, check again according to the wiring diagram. If the connection is proper, check the rated working voltage of the drive (this procedure is easy to be neglected, and thus cause severe damage and delay the test). If the supply voltage accords with the rated voltage, please set the drive in this method: First, set the parameters of the drive according to the rated parameters of the motor, such as rated rotation, torque and current. The objective of the test is to make the motor drives the work piece moving in specified instructions. We would like to introduce a new term, electronic gear ratio (similar to functional mechanical gearbox). Because the motors and mechanical transmission ratios are different, the unit pulse movements are different; therefore, it is necessary to select specific transmission ratio and motor during machinery manufacturing. The electronic gear ratio has solved this problem. The minimum instruction unit of this system is 0.001mm. A calculation formula follows: Pulses of every rotation of motor Gear at screw end Motion distance of every rotation mm*1000 Gear at motor end
CMR: Instruction magnification coefficient (system parameter 1 and 3) CMD: Instruction frequency division coefficient (system parameter 2 and 4)
The movement of every rotation is the lead of the screw Gears at screw end (indirect connection, has rotation ration) Gears at motor end (indirect connection, has rotation ration) If 403BM two-phase step drive and 56 two-phase motor, the screw lead is 4mm and the direct connection transmission ratio is 1:1 It is known from the manual of 403BM drive that the base working voltage is DC40V, and six coefficients are 2, 4, 8, 16, 32 and 64 respectively. The working current of the motor can be set. The step distance is 1.8 and the rated current is 3A. The drive uses 32 subdivisions and the current is set to 3A, and the electronic gear
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XS5 interface
Axis X positive limit travel switch xis X negative limit travel switch
The hard limit function is controlled by system parameters. Set the system parameter 22 hard limit enabling to 1 to enable the hard limit function, or set to 0 to disable the function. The system parameter 23 is hard limit effective level. Set the value (NO: 0, NC: 1) according to the actually connected switch type (NO, NC). After setting the hard limit parameters, move to the limit switch of every axis in low speed manually and check whether the parameters are set properly. To move to the positive limit switch of axis X, when the positive limit switch is enabled, axis X stops moving immediately and alarms, and wont move to the positive direction. To solve the problem, move to reverse direction to leave the limit switch, and press the Reset key to clear the alarm. Alarm info Axis X positive direction overtravel
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XS5 interface
Adjust the parameters according to the effective level of connection signal, origin mode and direction:
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test = 1: effective when disconnected from 0V = 0: effective when connected to 0V System parameter 41, 42: axis X and axis Z return to reference coordinates System parameter 35, 36: select positive or negative for the origin direction of axis X and axis Z System parameter 37, 38: high speed when axis X and axis Z return to origin System parameter 39, 40: low speed when axis X and axis Z return to mechanical origin After confirmed that the hard limit function and origin signal are effective, it is possible to
perform the mechanical origin operation. Check whether the origin switch is connected properly. For your safety, please move the axes to the center position manually and then switch to MDI mode. Switch to the input point interface, press the origin switch of every axis with hands, and the controller sends alarm tone. If there is no change, please check the corresponding external wiring. If the external wiring is proper, please check whether the machine tool input port is damaged. If yes, contact the system manufacturer. Perform the origin operation if the input signal is correct.
Generally, the mechanical origin is installed at the position of maximum travel. The effective travel of the origin block is at least 25mm. To ensure the accurate origin, please ensure sufficient deceleration distance, so that the speed can be reduced. The higher the mechanical origin speed is, the longer the origin block is. Otherwise, the origin accuracy will be affected because the system acceleration/deceleration and machine tool inertia make the mobile extension units cross the origin block and no sufficient deceleration distance is reserved. The diagram that uses one approach switch as the deceleration and origin signal at the same time follows:
Metal sensing block installed on the machine tool slide PNP-NC type approach switch Connect to +24V
Connect to 0V
I. The mechanical origin when use one approach switch as the origin signal The diagram follows:
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about 8mm
Metal sensing block installed on the machine tool NC type approach switch Direction to mechanical origin Connect to +24V DECN signal Connect to 0V
Origin process A: Select the mechanical origin mode, press the manual forward feeding key, and the corresponding axis moves to origin in high speed B: When the approach switch detects the block for the first time, the speed drops immediately and runs in fixed low speed reversely C: When the approach switch leaves the block, runs reversely in the decelerated speed, and starts checking the origin signal D: When the approach switch detects the block for the second time, the origin signal is valid, the movement stops and the mechanical origin operation completes II. Use one approach switch and servo origin as the mechanical origin of origin signal A: Select the mechanical origin mode, press the manual forward feeding key, and the corresponding axis moves to origin in high speed B: When the approach switch detects the block, the speed drops immediately and runs in fixed low speed, and starts checking the origin signal C: When it detects the servo origin for the first time, it runs reversely in fixed low speed D: If no servo origin signal is detected, it runs reversely in fixed low speed, and starts checking the servo origin signal (DEC). When it detects the servo origin signal for the second time, the origin signal is valid, the movement stops and the mechanical origin operation completes.
CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test N50 M30. Set the error compensation of reverse clearance to 0 before measuring; For single section program, find measurement reference A after positioning for two time, record current data, run 1mm in same direction and then run 1mm to point B in reverse direction to read current data. Reverse position
Position of reading data Diagram of reverse clearance measurement method Error compensation of reverse clearance = | data recorded by point Adata recorded by point B |; if the clearance error isnt 0, please modify the values of parameter 43 and 44 (unit: pulse); if the clearance is too big, increase the values of parameter 43 and 44, or else decrease the values until the error compensation of reverse clearance is 0. Note: Re-check the reverse clearance when the machine tool has been used for three months.
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test Parameters: system parameter 30 and 31, axis X and axis Z alarm level. Default: 0, low level is effective; if the alarm is high output level, please change this parameter to 1.
Parameters
System parameter 60: wire number of main axis encoder; please set according to the value marked on the encoder label.
Handwheel
The system doesnt respond to any operation when running screw thread instruction Reason: when lathing screw thread, system checks the signal of screw head (encoder axis Z signal). If the rising and falling of phase Z signal arent detected, the program stays in circle detection state (because the phase Z signal of the encoder is very narrow) and doesnt respond to the key-pressing.
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CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test Please check whether the connection of phase Z signal is normal. In main axis encoder test interface, press the Z key to enter the main axis encoder origin signal test method, as in the picture below Main axis encoder test Main axis encoder Handheld box test
Handwheel
Main axis encoder origin signal is normal
Rotate the encoder for four circles in low speed manually and the information in the picture below appears in normal condition. If the prompt that main axis encoder origin signal is normal doesnt appear after four circles, the phase Z signal of the encoder or the controller may be damaged. Please change the encoder. Main axis encoder test Main axis encoder Handheld box test
Handwheel
Main axis encoder origin signal test; please rotate the encoder for four circles
XS8 interface
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Frequency inverter
(Green)
(Red)
MDI mode The percentages in the table represent the ratio of theory output voltage and maximum voltage. Press the direction keys to select a percentage, use a multimeter to record the corresponding voltage and output to the table in the right. As in the figure above, press the direction key to select 50%, and the voltage measured with the multimeter is 4.62V. If it is same to the value in the table, it is not necessary to change. If not, input the measured value into the cell corresponding to 50%. The system shares two lines of analog voltage, and there are also two calibration parameter tables. Press the Up/Down key to switch the tables. If the parameters are in disorder, press the Reset key in MDI mode and stopped state to restore the default values. After the voltage calibration, set parameter 97 to 0.
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Chuck clamped
Chuck released
Digital input
Clamping signal
Release signal
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Chuck mode 2
Chuck mode 3
Chuck mode 0: continuous output control mode of internal chuck; chuck mode 1: continuous output control mode of external chuck; chuck mode 2: inching output control mode of internal chuck; chuck mode 3: inching output control mode of external chuck The difference between 0 and 2 of chuck clamping settings: if 2 is selected, main axis and chuck are interlocked. If the chuck clamping setting is 1, check the clamping in position signal. The principle of the four working mode follows: Chuck mode 0: while executing clamping instruction M12, open XS6-12 port and close XS6-13 port, and check the clamping in position signal pin XS5-8. If the clamping signal is detected in the clamping time of the chuck, the M12 instruction is executed; otherwise, send alarm info chuck clamping overtime. Chuck mode 1: while executing clamping instruction M12, open XS6-13 port and close XS6-12 port, and check the clamping in position signal pin XS5-7. If the clamping signal is detected in the clamping time of the chuck, the M12 instruction is executed; otherwise, send alarm info chuck clamping overtime. Chuck mode 2: while executing clamping instruction M12, open XS6-12 port and close XS6-13 port, delay chuck clamping time and then clock the XS6-12 port, and check the clamping in position signal pin XS5-8. If the signal is valid, the M12 instruction is executed; otherwise, send alarm info chuck clamping overtime. Chuck mode 3: while executing clamping instruction M12, open XS6-13 port and close XS6-12 port, delay chuck clamping time and then clock the XS6-13 port, and check the clamping in position signal pin XS5-7. If the signal is valid, the M12 instruction is executed; otherwise, send alarm info chuck clamping overtime. Note: when check the chuck clamping parameter settings: 0- do not check, do not interlock with main axis, 1- check the clamping signal and interlock with main axis, 2- do not check the clamping signal but interlock with main axis, 3- check the clamping signal but do not interlock with main axis
Tailstock forward
Tailstock backward
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Set the tailstock control to 1 to activate the tailstock function, or set it to 0 to deactivate the function. Note: Do not push the tailstock forward/backward when the main axis is rotating, or else the alarm occurs.
13.10. Knife replacing control 13.10.1 WIRING DIAGRAM OF ELECTRIC KNIFE RACK
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XS5 interface
Definition of J1 pins (knife rack signal - J1) 1) +24V -24V power output, provided for Hall elements; 2) Pin2-9 - 8 lines (two knife racks) Hall element signal input end, connected to Hall element signal output, (Hall element signal consists of NPN and PNP); 3) GND - earth of 24V power, provided for Hall elements;
Definition of J2 pins (Shaped signal - machine tool) 1) +24V -24V power input, connected to switching power supply or machine tool system 24 power supply; 2) Pin2-9 - 8 lines (two knife racks) Hall element signal input end, connected to machine tool system output; 3) GND - earth of 24V power, connected to switching power supply or earth of machine tool system 24 power supply;
JP9: 1) Pin2 and 3 short connected - corresponding output signal is NPN Hall element; 2) Pin1 and 2 short connected - corresponding output signal is PNP Hall element;
JP1-JP8: select the reverse phase of every line of input Depend on whether the output of Hall elements and the input of machine tool system are in same phase 1) Pin2 and 3 short connected - corresponding output of Hall elements and the input of machine tool system are in reverse phase; 2) Pin1 and 2 short connected - corresponding output of Hall elements and the input of machine tool system are in same phase;
A. No. 46 system knives Knife station (knife position) number for mechanical turret. Please select 0 for line knife structure. B. No. 47 knife position signal level the effective level of knife position sensor when the knife is in position C. No. 48 knife rack lock level select knife in positive rotation and lock in reverse rotation; the effective level of lock sensor D. No. 49 maximum knife replacing time the time that normal knife rack rotates one circle E. No. 50 lock delay time the delay time from the completion of knife selection in positive rotation to the start of reverse lock F. No. 51 knife rack reverse lock time the time required to lock the knife rack Note: the above parameters are effective to electric knife rack and the line knife doesnt require the setting.
Lock delay
13.11. Handheld box and additional panel interface XS7 13.11.1 INTERNAL WIRING DIAGRAM OF THE HANDHELD BOX
High X Medium
Emergency stop
Encoder
Definition Position switch (IN24) Position switch (IN26) Position switch (IN28) Button (IN30) Button (IN32) HA 24V-
Function Position 0.1 --- High speed Position 0.01--- Medium-speed Position 0.001--- Low speed Loop start Pause Phase A input signal for hand encoder Cathode of internal 24V power supply Anode of internal 24V power supply Axis X Axis Y Axis Z Axis A Emergency stop Phase B input signal for hand encoder Cathode of internal 24V power supply
1 2 3 4 5 6 7
5V+
9 10 11 12 13 14 15
Axis selection (IN25) Axis selection (IN27) Axis selection (IN29) Axis selection (IN31) Button (IN33) HB 5V-
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Emergency stop button Grey Red Black Yellow Blue Handwheel Pause (red)
The handheld box and additional panel share the interface XS7, and thus they can use only one function at the same time. Select the handheld box or additional panel through system parameter 86: if parameter 86 = 0, the handheld box is selected; if parameter 86 = 1, the additional panel is selected. The output signals of handheld box and additional panel have corresponding diagnosis signals on the controller, as in the figure below Main axis encoder test Main axis encoder Handheld box test
Handwheel
When any fault occurs, please set the operation mode to MDI, press the Diagnosis key to enter the diagnosis interface, and press the Up/Down key to switch to handheld box test interface, as in the figure above. Then, rotate and press the corresponding switch, and the corresponding diagnosis signal changes; otherwise, this signal has fault. Please check the connection of the signal wire and the switch. If normal, the input interface of the controller has internal fault. Please contact the manufacturer. When the handwheel is rotating, the counter shows the received pulses, and HNDA and HNDB signals change alternatively. If there is no counting, and HNDA and HNDB signals have no change, please check the wire connection and whether the 5V power supply of the handwheel is normal. If the connection is normal, but the handwheel doesnt have 5V power supply, the internal power supply of the controller has fault. Please contact the system manufacturer. Note: the 5V power supply is only for the handwheel.
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Lubrication
Cooling
RC absorber
RC absorber
Cooling motor
XS6 interface
Working indicator
Fault indicator
Fault indicator
Working indicator
XS6 interface
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13.14. Programmable I/O port 13.14.1 WIRING DIAGRAM OF PROGRAMABLE I/O PORT
XS5 interface
85
86
Filter
Green
Red
Fan (optional)
Power indicator
2 3
1~255 1~255
1 1
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1~255 1-9999 1-9999 1-9999 1-9999 1-9999 1-9999 1-9999 1-9999 1-9999 1-9999 1-9999 9999- (-9999) 9999- (-9999) 0-9999 0-9999 0-1 0-9999 0-1 0-1 0-1
1 4000 300 200 120 700 3000 3000 300 300 100 100 0 0 mm/min mm/min ms mm/min mm/min mm/min mm/min mm/min mm/min ms ms mm mm mm mm
0.02 0 50 1 0 1
mm/min
If 1 is selected, the values of parameter 25-28 are effective mm mm mm mm mm/min High/low High/low
25 26 27 28 29 30 31
Positive soft limit of axis X Negative soft limit of axis X Positive soft limit of axis Z Negative soft limit of axis Z Manual start speed Alarm level of axis X Alarm level of axis Z
32
Origin mode
0-2
0: low, 1: high 0: low, 1: high Origin mode =0: return to machine tool origin directly and do not check the origin switch Origin mode=1: deceleration switch origin Origin mode =2: deceleration switch and servo origin signal
87
33
0-1
36
0-1
37 38 39 40 41 42 43 44
High speed of axis X origin High speed of axis Z origin Low speed of axis X origin Low speed of axis Z origin Axis X reference point coordinates Axis Z reference point coordinates Axis X reverse clearance compensation Axis Z reverse clearance compensation
1-9999.99 1-9999.99 1-9999.99 1-9999.99 -9999.999-9999. 999 -9999.999-9999. 999 0-2 000 0-2 000
45
0-2
46 47 48 49 50 51 No. 52 53
System knives Knife position signal level Knife rack lock signal level Maximum knife replacing time Knife replacing delay Reverse lock time of knife rack Function Effective control position of chuck function Chuck mode
ms ms ms Unit Remark 0: ineffective 1: effective 0: continuous output of external chuck signal 1: continuous output of internal chuck signal 2: pulse output of external chuck signal 3: pulse output of internal chuck signal 1: check releasing and clamping signals; 0: do not check releasing and clamping signals; 2: check clamping signal; 3: check releasing signal
54
0-3
55 56 57 58
Chuck in position signal level Chuck clamping time Tailstock function control Main axis control mode
0 0
h 0: lubricate when the program is running; 1: lubricate when the system is electrified s May be changed in the program May be changed in the program
94 95 96 97
Lubrication output effective time Screw tail axis X speed ratio Screw tail axis Z speed ratio Regulation symbol of main axis analog quantity
0 0 0 0
89
Turn on program switch Turn on parameter switch Modify system parameter parameter switch Modify system parameter program switch Modify the numerator or denominator of the electronic gear ratio Modify the program Modify the program Please enter the password below Please set and return to program origin
90
91
1287 1288 1289 1290 1291 1292 1293 B001 B002 C000 C001 C003 C005 Alarm code C006 C009 C010 C013 C014 C017 C018
Screw thread interpolation speed is abnormal G90, G92 axis Z increment is 0 G94 axis X increment is 0 The system hasnt returned to the reference point Didnt specify the position of center point G30 didnt specify the position of center point M89 format error No memory chip or chip damaged "Memory chip is normal" System emergency stop Axis X drive alarm Axis Z drive alarm Axis X positive limit Content Axis X negative limit Axis Z positive limit Axis Z negative limit Axis X positive overtravel Axis X negative overtravel Axis Z positive overtravel Axis Z negative overtravel
Remark
CNC42 20 Ma c hi ne Too l Op e rat io n a nd Test DC driving motor stepless speed regulation: 3 Select 0 for line knife System knives Set the actual knives if turret knives are used Knife position High level effective: 1 signal level Low level effective: 0 Knife rack lock High level effective: 1 level Low level effective: 0 The time that the electric knife Maximum knife rack rotates one circle (unit: ms); set according to actual replacing time value The time from completion of positive knife selection to Lock delay time reverse lock delay; please set accordingly Knife reverse lock The time of the reverse lock of time the turret; please set accordingly Chuck function Chuck function on: 1 effective control Chuck function off: 0 position Internal chuck continuous output signal: 0 External chuck continuous output signal: 1 Chuck mode Internal chuck pulse output signal: 2 External chuck pulse output signal: 3 Do not check clamping signal: Check the chuck 0 Check clamping signal: 1 clamping Check clamping signal and interlock with main axis: 2 Chuck in position High level effective: 1 signal level Low level effective: 0 Chuck clamping The time of chuck clamping; time please set accordingly Tailstock function Tailstock function on: 1 control Tailstock function off: 0 Hard limit on: 1 Only for the Hard limit hard limit of Hard limit off: 0 enabled the chip Hard limit High level effective: 1 effective level Low level effective: 0
94
XS1 interface
XS1 interface
Drive
Drive
Example 2: Connection of CNC4220 and SGDM drive Example 1: Connection of CNC4220 and JaBao QS5 drive
Encoder
95
Axis X servo motor drive Axis X servo motor Example 3: Connection of CNC4220 and Q2BYG1106M step drive Axis X servo motor
96
XS5 interface
Axis X positive limit travel switch xis X negative limit travel switch
XS5 interface
97
Frequency inverter
(Green)
(Red)
Chuck clamped
Chuck released
Clamping signal
Digital input
Release signal
99
Tailstock forward
Tailstock backward
100
101
XS5 interface
Definition of J1 pins (knife rack signal - J1) 1) +24V -24V power output, provided for Hall elements; 2) Pin2-9 - 8 lines (two knife racks) Hall element signal input end, connected to Hall element signal output, (Hall element signal consists of NPN and PNP); 3) GND - earth of 24V power, provided for Hall elements;
Definition of J2 pins (Shaped signal - machine tool) 1) +24V -24V power input, connected to switching power supply or machine tool system 24 power supply; 2) Pin2-9 - 8 lines (two knife racks) Hall element signal input end, connected to machine tool system output; 3) GND - earth of 24V power, connected to switching power supply or earth of machine tool system 24 power supply; JP9: 1) Pin2 and 3 short connected - corresponding output signal is NPN Hall element; 2) Pin1 and 2 short connected - corresponding output signal is PNP Hall element;
JP1-JP8: select the reverse phase of every line of input Depend on whether the output of Hall elements and the input of machine tool system are in same phase 1) Pin2 and 3 short connected - corresponding output of Hall elements and the input of machine tool system are in reverse phase; 2) Pin1 and 2 short connected - corresponding output of Hall elements and the input of machine tool system are in same phase;
Knife position hall elements T01-T08 CNC9108 knife position signal adapter board
Lubrication
Cooling
RC absorber
RC absorber
Cooling motor
XS6 interface
103
104
Filter
Green
Red
For step drive Use step transformer if step motor is selected Fan (optional)
Use 24V switching power For CNC4240 supply if 24V electromagnetic controller valve is selected
Power indicator
Working indicator
Fault indicator
Fault indicator
XS6 interface
Working indicator
105